Key Technical Specifications

• Output Type: 24VDC Sourcing (Positive Logic)
• Channel Count: 2 Points per Module
• Redundancy: Triple Modular Redundancy (TMR) with 2oo3 Voting
• Isolation: 500 VDC Channel-to-Backplane
• Load Current: 2.0A Max per Point (Check datasheet for derating)
• Response Time: <10ms Typical
• Safety Rating: IEC 61508 SIL 3 / TUV AK6
• Power Source: 24VDC from Backplane
• Diagnostics: Open Circuit & Short Circuit Detection
• Termination: Requires 9662-Series Terminal Board

 

Product Introduction

Field wires get pinched, solenoids short out, and actuators stick. In a safety system, a single output failure shouldn’t trip the plant or, worse, fail to trip when needed. The TRICONEX 3625C1 exists to make those single-point failures irrelevant. It’s a 2-point digital output card that runs three independent output circuits in parallel. If one channel dies, the other two vote it out and keep driving the load. You get safety without spurious trips.I’ve installed hundreds of these in ESD and F&G panels. The 500VDC isolation isn’t just for show; it’s what keeps a field ground fault from frying your entire backplane. Just remember: this card sources 24VDC. If your field device needs a sink, you’re holding the wrong part. Also, the 2-point density means you burn a slot for two outputs. Plan your I/O count accordingly, or you’ll be buying more chassis later.

Quality SOP & Tech Pitfalls

The Lab Report:
Safety cards don’t get “trust me” passes. Every 3625C1 we ship goes through this:

1. Visual & Counterfeit Check: Microscope inspection of the TMR voting logic chips and output FETs. No rework, no fake date codes.
2. Live TMR Test: Installed in a Tricon test chassis. We force a channel fault and verify the 2oo3 vote holds and the diagnostic LED triggers.
3. Load & Isolation Test: Fluke 115 checks on 24VDC output regulation under load and 500VDC isolation resistance to backplane.
4. Firmware & Config Log: We read and record the module’s internal configuration. You need to know if it’s set for sourcing or if diagnostics are enabled.
5. Anti-Static Seal: Packed in verified ESD shielding with humidity indicator.

The Engineer’s Warning:
Here’s the classic 3625C1 trap: Wrong Terminal Board. This card requires a compatible 9662-series terminal board (like 9662-810 or 9662-910). I’ve seen guys plug it into a 9661 board and wonder why nothing works. The pinout is different. Also, don’t ignore the diagnostic LEDs. If the “ALARM” LED is on, the card has detected a field fault. Don’t just reset it. Find the short. I once had a client who kept resetting a faulted card until the output FET exploded. The short was in the solenoid coil, not the card.

 

Installation & Configuration Guide

1. Pre-Installation Safety: ⚠️ VERIFY SYSTEM STATE. Is the Tricon controller in RUN or STOP? Are you in a safe maintenance window? This is a safety-critical output. Confirm the loop is de-energized at the field device.
2. Documentation: Photograph the old 3625C1 and its terminal board. Note the slot number and any DIP switch/jumper settings on the terminal board. The card itself usually has no user jumpers, but the terminal might.
3. Removal: Label the field wires at the terminal board, not the card. Release the card’s ejector levers. Pull straight out. If it binds, stop. Check for bent backplane pins.
4. Installation: VERIFY TERMINAL BOARD COMPATIBILITY. Ensure you have a 9662-series board. Slide the 3625C1 in until the ejectors click. Tighten the captive screws. Do not overtighten.
5. Power-On & Test: Restore power. Watch the card LEDs. PWR should be green. FAULT should be off. In TriStation 1131, force the output ON and verify 24VDC at the terminal. Check the diagnostic page for “OK” status.

Compatible Replacement Models

• ✅ 3625C1: Exact drop-in replacement. Same specs, same terminal boards.
• ⚠️ 3625: Older revision. May require TriStation 1131 configuration update. Verify firmware compatibility.
• ❌ 3603B: Different output type (relay/contact). Not a direct replacement. Requires different terminal board and logic changes.

 

Frequently Asked Questions

Can I use this card for 120VAC outputs?
Absolutely not. The 3625C1 is strictly 24VDC sourcing. Applying AC or higher voltage will destroy the output FETs instantly and likely damage the backplane. For 120VAC, you need a 9661-series terminal board and a compatible relay output card (like 3603B or 3605E).My card has a solid red FAULT LED. What do I do?
Don’t just swap it. The FAULT LED means the card’s internal diagnostics have detected a problem. It could be an open circuit, a short to ground, or a short between channels. Use TriStation 1131 to read the specific diagnostic code. 90% of the time, it’s a field wiring issue, not a bad card. I’ve seen too many good cards returned as “defective” because the solenoid was shorted.Is this card hot-swappable?
Technically, yes, the Tricon system supports online module replacement. Practically, don’t do it unless you have to. Swapping a safety output card while the process is running is high-risk. If the new card has a different configuration or the field circuit is faulted, you could cause a spurious trip. Schedule it for a safe window.What terminal board do I need?
You need a 9662-series terminal board. Common part numbers are 9662-810 (24VDC commoned) or 9662-910 (24VDC with resistor protection). Do not use 9661-series boards. They are for 120VAC/120VDC relay outputs and have a completely different pinout.Can I mix 3625C1 and 3625 cards in the same chassis?
Yes, but they must be in separate slots. The Tricon backplane treats them as different module types. Just make sure your TriStation 1131 configuration matches the actual hardware. A mismatch will cause a configuration fault.How do I test the redundancy?
You can’t easily test the internal TMR voting without specialized test equipment. What you can test is the field circuit. Force the output ON and measure voltage at the terminal. Then, simulate a field open by disconnecting one wire (if safe). The card should detect the open and set a diagnostic alarm, but the output should remain ON via the other two channels. That’s your real-world redundancy check.